Egg carton



May 15, 1962 J. w. cox 3,034,693

EGG CARTON Filed Nov. 22, 1955 2 Sheets-Sheet 1 May 15, 1962 J. w. cox 3,034,693

ECG CARTON Filed Nov. 22, 1955 2 Sheets-Sheet 2 IVNTOR.

@iemMljJW/r Wm 3,034,693 EGG CARTON John W. Cox, Chicago, Ill., assignor to The Diamond National Corporation, a corporation of Delaware Filed Nov. 22, 1955, Ser. No. 548,389 4 Claims. (Cl. 2292.5)

This invention relates to egg cartons and is particularly concerned with improvements in a carton having a cellular bottom and a separable cover therefor wherein the eggs are effectively cushioned and supported in the lower of the two sections without objectionably increasing the overall carton size and wherein the two sections of the carton are effectively braced by one another in the closed condition thereof.

It is a general object of the invention to provide an egg carton which is characterized by a non-cellular cover and a cellular bottom which divide the carton into two sections, intermediate its height, with the bottom having provisions for internally bracing the cover when it is posi tioned thereon to prevent lateral shifting thereof relative to the bottom and with cooperating locking formations which are automatically operative upon positioning the cover on the bottom to hold the two sections in locked relation and which may be readily released for removal of the cover without damage to the eggs therein.

More specifically, the invention provides an egg carton having separable cover and bottom sections wherein the bottom section is provided with internal cover bracing and locking flanges which are integrally carried on the side margins thereof, 'with the flanges arranged to telescope slidingly upwardly in the cover section as the latter is brought down toward the bottom section and to assume face-to-face engagement with the front and rear walls of the cover section, together with externally projecting locking lugs integrally molded on the flanges and cooperating locking apertures molded in the walls of the cover section and adapted to receive the locking lugs under an inherent outward spring of the flanges about their integral connection to the bottom.

It is a further object of the invention to providea' molded pulp egg carton having separable cover and bottom sections wherein thebottom section is provided with upwardly extending cover bracing flanges along opposite side edges thereof and an integrally molded internal partition structure which ties the bottom section together as a rigid box-like unit and stabilizes and stiffens the integral longitudinal hinges which connect the flanges to the bottom section with the result that a spring action of the flanges about the hinges is obtained as the flanges are swung inwardly to upright position which insures snap engagement of the flange locking elements in the cover apertures when the flanges are fully telescoped within the cover walls.

It is another object of the invention to provide a carton having separable cover and bottom sections wherein the bottom section is provided with integral upstanding bracing and locking flanges for cooperation with the walls of the cover, the flanges and the cover walls being molded so that the cover walls will slide over the outer faces of the flanges as the carton sections are engaged and disengaged without regard to the presence or absence of eggs in the cells of the bottom section and the flanges having locking lugs which will interlock in cooperating apertures provided in the cover section without subjecting the eggs, when the carton is filled, to any wedging or crushing as the cover section is closed over the flanges and the bottom section with the result that the locking action is equally effective whether the carton is wholly or partially filled.

It is a further object of the invention to provide an egg carton of the character described wherein the up Bfidififl Patented May 15, 1962 standing bracing and locking flanges are so arranged relative to the cell structure in the bottom section that they have side engagement with eggs in the cells adjacent their hinges only at a zone slightly above their zone of girth, even for the largest size of eggs which can be housed in the carton, and a substantial top space is left at the centers of the egg cells and between the flanges in the upwardly receding curvatures of eg s in those cells into which the flange can be flexed inwardly a substantial dis tance as its locking lugs are depressed to release the same, with the inherent hinge spring of the flanges resisting release of the lugs and not the abutment of the same against the eggs in the cells since there is no appreciable contact of the flanges with the eggs at the vertical planes of the lugs themselves which are located between the egg cells.

It is another object of the invention to provide in an egg carton of the type described cover and bottom sections which are separable and in which the bottom section is provided with upstanding flanges along the edges thereof which are provided with locking lugs adjacent their tops for reception in apertures in the side walls adjacent the top of the cover so that there is a maximum free moment arm between each lug and the adjacent eggs andthe lugs may be disengaged with ease and convenience from the cover apertures in opening the carton.

It is another object of the invention to provide an egg carton comprising a cellular bottom and a non-cellular cover which are separable on a plane intermediate the height of the carton whereby the cover and bottom sections may be produced from different materials or by different production methods thereby facilitating the production of the carton sections and providing substantial advantages by reason of the use of diiferent materials for the two sections or different production techniques and permitting greater flexibility in the treatment of the sections particularly the cover section which may be made of a variety of materials of poorer or better grade than the bottom section, which may be made wholly or partially of transparent materials to expose the contents of the container to view, which may be made of different colors, of lighter weight, of higher grade materials for better printing or provided with other different physical qualities from the bottom section which will enhance the appearance of the carton and provide advantages in dis play use when the cover is removed.

These and other objects and advantages of the invention will be apparent from a consideration of the egg carton which is shown by way of illustration in the accompanying drawings wherein:

FIG. 1 is a perspective View of a carton which embodies therein the principal features of the invention;

FIG. 2 is an exploded perspective view of the carton showing the cover removed from the bottom and several of the eggs taken out of one end thereof;

FIG. 3 is a plan view of the cover section of the carton showing the inside thereof;

FIG. 4 is a plan view of the bottom of the carton in the open generally planar condition thereof as stripped from molding and drying dies;

FIG. 5 is a front elevation of the carton in closed and locked condition, with portions being broken away to more clearly illustrate the character and action of the internal locking flange and lugs thereof;

FIG. 6 is a cross section on the line 66 of FIG. 5;

FIG. 7 is a cross section on the line '77 of FIG. 5;

FIG. 8 is a cross section on the same plane as in FIG. 7, showing the action in releasing the locking lugs; and

FIG. 9 is a fragmentary section on a horizontal plane along theline 9-9 of FIG. 5 showing in solid and dotted lines how the carton permits inward flange flexure and disengagement of its lock.

The illustrated carton comprises a cellular pronounceably compartmented bottom section, generally designated at 10, and a tray-like non-cellular cover section 11 which is adapted to be positioned on the upwardly opening face of the bottom section when the carton is closed.

The interior of bottom section 10 is partially subdivided into two rows of six egg receiving cells 12, in the type of carton chosen for illustration, by longitudinally extending series of upstanding center separator posts 13 which are of generally rectangular outline at their tops. The sides of the separator posts 13 merge downwardly in a concave shape as at 14 and at an angle to the vertical into the flat lower cell walls 15 which are arranged in rectangular outline. The floor of each cell 12 has a convexly rounded cushioned button 16 molded therein which will afford a yieldable support for a relatively small egg. The primary cushioned vertical support is, however, at the flat divergent wall surfaces 15. Spaced, inwardly extending side and end abutment webs 17 along the respective side and end walls 18 and 19 of bottom section 10 complete the cellular partition structure of the latter. They have generally conical upper and flat lower cell defining surfaces which merge beneath the cell tops in like manner to the surfaces 14 and 15 of central posts 13. The cells 12 are contiguous in their longitudinal and transverse arrangements, that is, the spacing of the bottoms of successive cells 12 brings them so close to one another that adjacent, upwardly tapering flat surfaces 15 meet well below the top of the cells, in fact at an elevation a little more than midway of the cell height, as appears in FIG. 6. This is true of any pair of successive cells whether arranged transversely of the carton or in one of its longitudinal rows. The merger of successive contiguous cells occurs approximately at, and not below, the elevation at which the respective sets of lower flat surfaces 15 merge upwardly into the conical surfaces 14. The result is that downwardly curved intermediate ridges or saddle-shaped portions 20 integrally connect successive posts 13 with one another, in the longitudinal direction and integrally connect each post with abutment ledges or webs 17 on the underside thereof, in the transverse direction. These depressed connections are of slight width, their cross section representating a somewhat thickened apex of the upwardly convergent surfaces 15, and they are concavely curved in their transverse contour. Thus eggs in successive cells are brought as close together as possible, for the larger sizes, yet they are safely protected against contact by the upwardly tapered cell dividers 20 and posts 13. The conical upper surfaces 14 of the posts 13 and side and end abutments 17 cradle the maximum girth of the eggs, restraining them from contact and holding them from rolling when the carton is opened. In the practice it has been found best to taper the lowermost flat cell surfaces 15 at an angle of about 28 to the vertical, with the upper conical surfaces at a substantially lesser angle, as shown in FIG. 6. This provides the desired cushioned egg supported surfaces 15 and the best horizontal egg restraint at its zone of approximately maximum girth. Thus the cellular bottom section 10 of the carton is made up of cells which are contiguous well beneath the tops and above the bottoms thereof, providing the maximum compacting of the overall longitudinal and transverse dimensions of the carton as a whole, which will enable the cells to accommodate large size eggs without their destructive contact with one another to hold the eggs against excessive tilt or shift. The partitioning means extend integrally from end to end and side to side of the carton thus substantially rigidifying the same.

Elongated internal cover bracing and locking flanges 21 are integrally hinged by longitudinally extending creases 22 to the side margins of bottom section 10 at the top edge of the side walls 18 thereof. The flanges 21, are of generally scalloped outline. Each flange 21 has egg accommodating bays or recesses 23 which are in transverse alignment with the bottom section egg cells 12 and intervening inwardly projecting abutments 24 which are transversely aligned with the side abutmeuts 17 of the bottom 10. The flanges 21 each carry a pair of lock ing elements or lugs 25 which are integrally molded in the flange 21 to project outwardly adjacent the free outer edge thereof. The lugs or locking elements 25 are characterized by upper and lower surfaces 26 and 26', respectively, which angle divergently and merge with the remainder of the flange 21 above and below the lugs. A rounded nose 27 connects the lug surfaces 26 and 26.

The cover section 11 of the carton has pairs of opposed end walls 28 and side walls 29 integrally joined by rounded corners 30 and a flat top panel 31 is likewise integrally joined about its periphery with the side and end walls. The exterior surface of this panel is smooth and continuous, well suited for the reception of printed matter or ornamentation. The side walls 29 are of generally scalloped outline corresponding to the scalloped outline of the upstanding flange formations 21 on the bottom section 10, and are characterized by longitudi-- nally spaced, outwardly curved or recessed bays 32 which are adapted to increase the egg room in the cover section; above the egg cells in the bottom section. The recesses. 32 are spaced by intervening, inwardly extending abutment portions 33 which abutment portions 33 have stable vertical engagement with the abutment portions 17 on. the cellular bottom section 10 when the carton is closed.

The cover section 11 is provided in its side walls 29 with locking apertures 34 extending upwardly from an in-- termediate point in the height of the cover side walls 29 to the junction with top panel 31 of the cover section as illustrated in FIGS. 5 and 7. The locking apertures 34- cooperate with the locking lugs or elements 25 on the: upstanding facing flanges 21 of the bottom section 10 when the carton is closed. The apertures 34 are of generally rectangular shape and somewhat larger than the size of the lugs 25 so that they may readily receive the; latter. The locking and bracing flange 21 is of a height. to also extend to the top panel 31, being in edge abutting and vertically bracing engagement with the latter, as. well as internal, side by side contact with the inner surface of the apertured cover walls 29 when the carton is closed and locked as in FIG. 7. However, it would be noted that in this condition the flanges 21 are readily" flexible inwardly to disengage the lock as an inspection of FIGS. 7, 8 and 9 will reveal. FIG. 9, which depicts inv dot and dash lines the shape or outline of eggs at the elevation in which the section is taken, shows a substan tial space between the eggs and the flanges 21 which permits freedom of inward flange flexure.

In using the carton eggs are deposited, large end up, inbottom section cells 12, whereupon the flanges 21 are swung to upstanding position adjacent the opposite side margins and the cover section 11 is moved downwardly into externally telescoped relation over the flanges 21. These operations may be performed on high speed closing apparatus adapted to plough the flanges 21 inwardly about their hinges and drop the cover thereon. As this happens, the free cover walls 29 slide downwardly over the upperinclined camrning surface 26 of the flange locking lugs 25 flexing the wall 29 outwardly somewhat, if necessary, to cause the cover to clear the flanges. When the lower edge of each Wall aperture 34 passes the nose 27 of its locking lug the latter snaps outwardly under the inherent spring of the flange 21 to a positively interlocked relationship in the aperture. The lower inclined surface 26 of the lug 25 facilitates its entry into the aperture without snagging and the inclination exerts some cam action on the cover wall to urge it in a downward direction as it is seated thereon. Each flange 21 is in edge abutting, load sustaining relation to the cover top panel 31 when the cover is fully closed. In its inherent outward spring it urges it outwardly to maintain this relationship to the cover and to resist accidental inward displacement of the locking lugs 25 from the apertures 34. Thus locking engagement is completed without jamming the flanges 21 inwardly under substantial force which would be apt to crush the eggs.

In order to unlock the cover 11 the lugs 25 are pressed inwardly in the fashion illustrated in FIG. 8, the oppositely disposed lugs 25 being engaged by the thumb and one of the other fingers of the hand and the cover is lifted by the fingers as the lugs 25 are depressed inwardly. As can be seen from FIGS. 8 and 9, there is a substantial space between the upper part of the flange 21 and the receding upper curvature of an egg to permit readily inward flexure of the flange 21 upon the lugs being depressed inwardly, the inward spring of the flange 21 being facilitated by the arrangement of the lugs in the top portion of the flange immediately adjacent its free upper edge. The most restricted space is at the longitudinal center of an egg cell, as depicted in FIG. 6, and it is there indicated in dotted line as the flanges 21 can flex inwardly at their top to accommodate inward shift of the lugs 25 in a zone to one side of the eggs. The eggs will not ordinarily be engaged by the flanges 21 at an elevation as much as midway of the height of the cover section 11. There is a maximum moment arm between the lug 25 and this point of egg flange engagement for inward yielding of the flange and unlocking of the carton.

The cover 10 and the bottom section 11 of the carton may both be molded of the same pulp stock or the two sections of the carton may be molded of stock of diflerent character and thus achieve variations not possible with connected carton sections. The cover section which is utilized for display purposes may be made of a different stock in order to improve its appearance or permit the use of different decorative schemes. The cover may be wholly or partially formed of a transparent material to permit the purchaser to observe all or part of the contents of the carton in its closed condition. The cover section may be formed from pressed paper or in some other manner, if desirable, which would permit the use of diflerent type machines for the manufacture of the two carton sections.

While specific materials and particular details of construction are referred to in describing the illustrated form of the carton, it will be understood that other materials and other details of construction may be resorted to within the spirit of the invention.

I claim:

1. A carton comprising separable bottom and cover sections, said bottom section comprising a plurality of upwardly opening egg cells arranged in row formation therein, said egg cells merging at a plane that is intermediate the upper and lower boundary planes of said bottom section, said cells below said intermediate plane extending downwardly and being spaced from each other, to thereby provide a plurality of spaced supporting feet for said carton bottom section, said cells each tapering downwardly from said intermediate plane, said cover section having a generally planular top and a pair of side walls and a pair of end walls joined thereto, said walls flaring outwardly at an angle that is at least as great as the angle of taper of said cells, the interior width of said cover section top being at least as wide as the width of said bottom section across said cells providing said supporting feet, the interior length of said cover section top being at least as long as the length of said bottom section across said cells providing said supporting feet, whereby said cover section may be placed under said bottom section to provide a planular support for the sup porting feet of said bottom section, an upstanding flap hingedly connected to said carton bottom section along the top of opposite side edges thereof, and interengaging means on said flaps and said cover section side walls for releasably locking said cover section in position onto said bottom section, said inte-rengaging means on the flap and side wall on one side of the carton being diametrically opposite to the interengaging means on the flap and side wall on the other side of the carton, whereby said side walls and flaps will mutually and interchangeably interengage.

2. An egg carton comprising an elongated bottom section of pressed pulp provided with two longitudinal rows of egg pockets for receiving and holding eggs in an upright position, said pockets adapted to accommodate the lower portions only of said eggs with the upper portions of the eggs extending from said pockets and exposed above said bottom section, a separate hollow cover of a different material on said bottom section having upwardly tapered sides disposed alongside said rows of egg pockets and ends disposed at the ends of said rows, said cover adapted to receive the upper portions of said eggs and being transparent to render said eggs visible through said cover, integral outwardly biased hinged flaps on opposite longitudinal sides of said bottom section extending upwardly under the tapered sides of said cover, said flaps adapted to be interposed between the upper portions of said eggs and the sides of the cover and being confined by the latter to hold said eggs in said pockets, said flaps cushioning upward movement of said eggs out of said pockets to prevent breakage thereof against said cover, and snap-lock means on said cover sides and said flaps for detachably holding said cover on said bottom section, said means comprising openings in said tapered sides of the cover and cooperating projections on the outwardly biased hinged flaps which snap-lock into said cover openings on downward movement of said cover so that the tapered sides thereof move downwardly on said side flaps when said bottom section has eggs disposed in the pockets thereof.

3. A carton comprising separable bottom and cover see tions, said bottom section comprising a plurality of upwardly opening egg cells arranged in row formation therein, said cells being connected together and extending downwardly and being spaced from each other, to thereby provide a plurality of spaced supporting feet for said oar-ton bottom section, said cover section having a generally planular top and a pair of side walls and a pair of end walls joined thereto, said walls flaring outwardly at an angle, the interior width of said cover section top being at least as wide as the width of said bottom section across said cells providing said supporting feet, the interior length of said cover section top being at least as long as the length of said bottom section across said cells providing said supporting feet, whereby said cover section may be placed under said bottom section to provide a planular support for the supporting feet of said bottom section, an upstanding flap hingedly connected to said carton bottom section along the top of opposite side edges thereof, and interengaging means on said flaps and said cover section side walls for releasably locking said cover section in position onto said bottom section, said interengaging means on the flap and side wall on one side of the carton being diametrically opposite to the intereng-aging means on the flap and side wall on the other side of the carton, whereby said side walls and flaps will mutually and interchangeably interengage.

4. An egg carton comprising an elongated bottom section of pressed pulp provided with two longitudinal rows of egg pockets for receiving and holding eggs in an upright position, said pockets adapted to accommodate the lower portions only of said eggs with the upper portions of the eggs extending from said pockets and exposed above said bottom section, a separate hollow cover on said bottom section having upwardly tapered sides disposed alongside said rows of egg pockets and ends disposed at the ends of said rows, said cover adapted to receive the upper portions of said eggs, integral outwardly biased hinged flaps on opposite longitudinal sides of said bottom section extending upwardly under the tapered sides of said cover, said flaps adapted to be interposed between the upper portions of said eggs and the sides of the cover and being confined by the latter to hold said eggs in said pockets, said flaps cushioning upward movement of said eggs out of said pockets to prevent breakage thereof against said cover, and snap-lock means on said cover sides and said flaps for detachably holding said cover on said bottom section, said means comprising openings in said tapered sides of the cover and cooperating projections on the outwardly biased hinged flaps which snap-lock into said cover openings on downward movement of said cover so that the tapered sides thereof move downwardly on said side flaps when said bottom section has eggs disposed in the pockets thereof.

References Cited in the file of this patent UNITED STATES PATENTS 1,906,639 Sherman May 2, 1933 2,088,603 Kronenberger Aug. 3, 1937 2,093,280 Koppelman Sept. 14, 1937 FOREIGN PATENTS 400,843 Great Britain Nov. 2, 1933 519,488 Belgium Oct. 26, 1953 

